The Ti6Al4V alloy is highly mechanical, corrosion-resistant, low-specific weight, and biocompatible. Several high-performance applications are ideal for technical uses in the auto, aerospace, and medical sectors. The recent process parameters for Ti6Al4V, manufactured using additive manufacturing methods, are reviewed in this article for the past 20 years. It is possible to link processing parameters with fundamental information. This review finds that the process parameters in additive manufacturing are laser power, scanning speed, layer thickness, and hatch distance. In addition, this reviewed the presence of processes in the additive manufacturing of Ti6Al4V components and their impact on mechanical performance and microstructure analysis. In the additive manufacturing process, the reviewed parameter is the additive manufacturing component that has reduced the defects of microstructural evaluation, residual stress, porosity, compression, and corrosion behaviour of the study.
SafaviMSBordbar-KhiabaniAKhalil-AllafiJ, et al.Additive manufacturing: an opportunity for the fabrication of near-net-shape NiTi implants. J Manuf Mater Process2022; 6: 65.
2.
DalpaduloEPetruccioliAGherardiniF, et al.A review of automotive spare-part reconstruction based on additive manufacturing. J Manuf Mater Process2022; 6: 133.
YangLHsuKBaughmanB, et al.Additive Manufacturing of Metals: The Technology, Materials, Design and Production. Cham: Springer International Publishing, Epub ahead of print 2017.
5.
Calleja-OchoaAGonzalez-BarrioHLópez de LacalleN, et al.A new approach in the design of microstructured ultralight components to achieve maximum functional performance. Materials (Basel)2021; 14: 1588.
6.
ZhangYZhangJ. Finite element simulation and experimental validation of distortion and cracking failure phenomena in direct metal laser sintering fabricated component. Addit Manuf2017; 16: 49–57.
7.
GajeraHMDaveKGDarjiVP, et al.Optimization of process parameters of direct metal laser sintering process using fuzzy-based desirability function approach. J Braz Soc Mech Sci Eng2019; 41: 124.
8.
RossiSDeflorianFVenturiniF. Improvement of surface finishing and corrosion resistance of prototypes produced by direct metal laser sintering. J Mater Process Technol2004; 148: 301–309.
9.
SimchiAAsgharzadehH. Densification and microstructural evaluation during laser sintering of M2 high speed steel powder. Mater Sci Technol2004; 20: 1462–1468.
10.
LiuFRZhaoJJZhangQ, et al.Processing and characterizations of 2%PF/silica sand core–shell composite powders by selective laser sintering with a higher transmittance fiber laser. Int J Mach Tools Manuf2012; 60: 52–58.
11.
ZhuHHFuhJYHLuL. The influence of powder apparent density on the density in direct laser-sintered metallic parts. Int J Mach Tools Manuf2007; 47: 294–298.
12.
ManganoFChambroneLvan NoortR, et al.Direct metal laser sintering titanium dental implants: a review of the current literature. Int J Biomater2014; 2014: 1–11.
13.
MierzejewskaŻA. Effect of laser energy density, internal porosity and heat treatment on mechanical behavior of biomedical Ti6Al4V alloy obtained with DMLS technology. Materials (Basel)2019; 12: 2331.
14.
HadadzadehAAmirkhizBSLiJ, et al.Columnar to equiaxed transition during direct metal laser sintering of AlSi10Mg alloy: effect of building direction. Addit Manuf2018; 23: 121–131.
15.
PromoppatumPOnlerRYaoS-C. Numerical and experimental investigations of micro and macro characteristics of direct metal laser sintered Ti-6Al-4V products. J Mater Process Technol2017; 240: 262–273.
16.
StübingerSMoschIRobottiP, et al.Histological and biomechanical analysis of porous additive manufactured implants made by direct metal laser sintering: a pilot study in sheep: analysis of porous additive manufactured implants. J Biomed Mater Res B Appl Biomater2013; 101: 1154–1163.
17.
SimchiAPetzoldtFPohlH. On the development of direct metal laser sintering for rapid tooling. J Mater Process Technol2003; 141: 319–328.
18.
MahantheshaPMohankumarGC. Microstructure and mechanical properties of nickel coated multi-walled carbon nanotube reinforced stainless steel 316L matrix composites by laser sintering process. Karnataka, India, p.020098.
19.
HrabeNGnäupel-HeroldTQuinnT. Fatigue properties of a titanium alloy (Ti-6Al-4V) fabricated via electron beam melting (EBM): effects of internal defects and residual stress. Int J Fatigue2017; 94: 202–210.
20.
QiuCAdkinsNJEAttallahMM. Microstructure and tensile properties of selectively laser-melted and of HIPed laser-melted Ti-6Al-4V. Mater Sci Eng A2013; 578: 230–239.
21.
LeudersSThöneMRiemerA, et al.On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: fatigue resistance and crack growth performance. Int J Fatigue2013; 48: 300–307.
22.
KasperovichGHausmannJ. Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting. J Mater Process Technol2015; 220: 202–214.
23.
AlcistoJEnriquezAGarciaH, et al.Tensile properties and microstructures of laser-formed Ti-6Al-4V. J Mater Eng Perform2011; 20: 203–212.
24.
HayesBJMartinBWWelkB, et al.Predicting tensile properties of Ti-6Al-4V produced via directed energy deposition. Acta Mater2017; 133: 120–133.
25.
VranckenBThijsLKruthJ-P, et al.Heat treatment of Ti6Al4V produced by selective laser melting: microstructure and mechanical properties. J Alloys Compd2012; 541: 177–185.
26.
IshfaqKAbdullahMMahmoodMA. A state-of-the-art direct metal laser sintering of Ti6Al4 V and AlSi10Mg alloys: surface roughness, tensile strength, fatigue strength and microstructure. Opt Laser Technol2021; 143: 107366.
27.
DangJLiuGChenY, et al.Experimental investigation on machinability of DMLS Ti6Al4V under dry drilling process. Mater Manuf Process2019; 34: 749–758.
28.
ChangJZ-CTsaiP-IKuoMY-P, et al.Augmentation of DMLS biomimetic dental implants with weight-bearing strut to balance of biologic and mechanical demands: from bench to animal. Materials (Basel)2019; 12: 164.
29.
SingSLHuangSGohGD, et al.Emerging metallic systems for additive manufacturing: in-situ alloying and multi-metal processing in laser powder bed fusion. Prog Mater Sci2021; 119: 100795.
30.
ZenaniADzogbewuTCPreezWBD, et al.Optimum process parameters for direct metal laser sintering of Ti6Al powder blend. Univers J Mech Eng2020; 8: 170–182.
31.
QinYQiQShiP, et al.Automatic generation of alternative build orientations for laser powder bed fusion based on facet clustering. Virtual Phys Prototyp2020; 15: 307–324.
BaumersMTuckCWildmanR, et al.Shape complexity and process energy consumption in electron beam melting: a case of something for nothing in additive manufacturing?: shape complexity and energy usage in 3D printing. J Ind Ecol2017; 21: S157–S167.
34.
BerminghamMJNicastroLKentD, et al.Optimising the mechanical properties of Ti-6Al-4V components produced by wire + arc additive manufacturing with post-process heat treatments. J Alloys Compd2018; 753: 247–255.
35.
JardiniALCostaMCBBineliARR, et al.Operability analysis and conception of microreactor by integration of reverse engineering and rapid manufacturing. Comput Aided Chem Eng2008; 25: 853–858.
36.
BineliARRPeresAPGJardiniAL, et al.Direct Metal Laser Sintering (DMLS): Technology For Design And Construction Of Microreactors.
37.
CalignanoFManfrediDAmbrosioEP, et al.Direct fabrication of joints based on direct metal laser sintering in aluminum and titanium alloys. Procedia CIRP2014; 21: 129–132.
38.
AzizIAGabbitasBStanfordM. Direct metal laser sintering of a Ti6Al4V mandible implant. Key Eng Mater2012; 520: 220–225.
39.
NovotnýLBérešMde AbreuHFG, et al.Thermal analysis and phase transformation behaviour during additive manufacturing of Ti-6Al-4V alloy. Mater Sci Technol2019; 35: 846–855.
40.
ChandramohanPBheroSObadeleBA, et al.Effect of built orientation on direct metal laser sintering of Ti-6Al-4V. Indian J Eng Mater Sci2018; 25: 69–77.
41.
RibamarGGMouráo dos SantosLPCoelhoHL, et al.Study of phase transformation in Ti-6Al-4V alloy produced by direct metal Laser sintering. In: VenkateshVPilchakALAllisonJE, et al. (eds) Proceedings of the 13th world conference on Titanium. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2016; pp.1295–1298.
42.
LarosaMJardiniABernardesL, et al.Custom-built implants manufacture in titanium alloy by direct metal Laser sintering (DMLS). In: da Silva BártoloPde LemosAPereiraA, et al. (eds) High value manufacturing: advanced research in virtual and rapid prototyping. CRC Press, 2014; pp.297–301.
43.
LarosaMAJardiniALZavagliaCA, , et al.Microstructural and mechanical characterization of a custom-built implant manufactured in titanium alloy by direct metal laser sintering. Adv Mech Eng2014; 6: 945819.
44.
MuiruriAMaringaMdu PreezW, et al.Effect of stress-relieving heat treatment on the high strain rate dynamic compressive properties of additively manufactured Ti6Al4 V (ELI). Metals (Basel)2020; 10: 653.
45.
BrezinováJHudákRGuzanováA, et al.Direct metal laser sintering of Ti6Al4V for biomedical applications: microstructure, corrosion properties, and mechanical treatment of implants. Metals (Basel)2016; 6: 171.
46.
BertolLSSilvaFPKindlein JuniorW. Design and health care: a study of virtual design and direct metal laser sintering of titanium alloy for the production of customized facial implants. Australas Med J2008; 2: 136–141.
47.
Kumar MauryaNSharmaRKumarN, et al.An overview of investigation of fatigue, tensile strength and hardness of the components fabricated through direct metal laser sintering (DMLS) process. Mater Today Proc2021; 47: 3979–3984.
48.
KarolewskaKLigajBBorońskiD. Strain analysis of Ti6Al4V titanium alloy samples using digital image correlation. Materials (Basel)2020; 13: 3398.
49.
KarolewskaKLigajBWirwickiM, et al.Strength analysis of Ti6Al4V titanium alloy produced by the use of additive manufacturing method under static load conditions. J Mater Res Technol2020; 9: 1365–1379.
50.
KunzLPokornýPKonečnáR, et al.Propagation of long fatigue cracks in Ti6Al4V alloy produced by direct metal laser sintering. Procedia Struct Integr2019; 17: 222–229.
51.
KonečnáRNicolettoGBačaA, et al.Metallographic characterization and fatigue damage initiation in Ti6Al4V alloy produced by direct metal laser sintering. Mater Sci Forum2017; 891: 311–316.
52.
BačaAKonečnáRNicolettoG. Influence of the direct metal laser sintering process on the fatigue behavior of the Ti6Al4V alloy. Mater Sci Forum2017; 891: 317–321.
53.
KonečnáRKunzLBačaA, et al.Resistance of direct metal laser sintered Ti6Al4V alloy against growth of fatigue cracks. Eng Fract Mech2017; 185: 82–91.
54.
MalefaneLBdu PreezWMaringaM. High cycle fatigue properties of as-built Ti6Al4V (ELI) produced by direct metal laser sintering. South Afr J Ind Eng2017; 28: 188–199.
55.
KonečnáRNicolettoGFintováS, et al.As-built surface layer characterization and fatigue behavior of DMLS Ti6Al4V. Procedia Struct Integr2017; 7: 92–100.
56.
KonečnáRKunzLBačaA, et al.Long fatigue crack growth in Ti6Al4V produced by direct metal laser sintering. Procedia Eng2016; 160: 69–76.
57.
BačaAKonečnáRNicolettoG, et al.Influence of build direction on the fatigue behaviour of Ti6Al4V alloy produced by direct metal laser sintering. Mater Today Proc2016; 3: 921–924.
58.
ŚliwaREBernaczekJBudzikG. The application of direct metal laser sintering (DMLS) of titanium alloy powder in fabricating components of aircraft structures. Key Eng Mater2016; 687: 199–205.
59.
van ZylIYadroitsavaIYadroitsevI. Residual stress in Ti6Al4V objects produced by direct metal laser sintering. South Afr J Ind Eng2016; 27: 134–141.
60.
BeckerTHBeckMSchefferC. Microstructure and mechanical properties of direct metal laser sintered TI-6AL-4V. South Afr J Ind Eng2015; 26: 1.
61.
GreitemeierDDalle DonneCSyassenF, et al.Effect of surface roughness on fatigue performance of additive manufactured Ti-6Al-4V. Mater Sci Technol2016; 32: 629–634.
62.
SharmaMSoniM. Direct metal laser sintering of TI6Al4V alloy for patient-specific temporo mandibular joint prosthesis and implant. Mater Today Proc2021; 38: 333–339.
63.
SoyamaHTakeoF. Effect of various peening methods on the fatigue properties of titanium alloy Ti6Al4V manufactured by direct metal laser sintering and electron beam melting. Materials (Basel)2020; 13: 2216.
64.
MierzejewskaŻAHudákRSidunJ. Mechanical properties and microstructure of DMLS Ti6Al4V alloy dedicated to biomedical applications. Materials (Basel)2019; 12: 176.
65.
MalzSNosirSTrudelEP, et al.Effect of ultrasonic impact treatment on the stress-controlled fatigue performance of additively manufactured Ti-6Al-4V alloy. In: AIAA Scitech 2019 Forum. San Diego, California: American Institute of Aeronautics and Astronautics, 2019.
66.
NicolettoGKonečnáRFrkáňM, et al.Surface roughness and directional fatigue behavior of as-built EBM and DMLS Ti6Al4V. Int J Fatigue2018; 116: 140–148.
67.
GuDShenY. Balling phenomena in direct laser sintering of stainless steel powder: metallurgical mechanisms and control methods. Mater Des2009; 30: 2903–2910.
68.
IslamMPurtonenTPiiliH, et al.Temperature profile and imaging analysis of laser additive manufacturing of stainless steel. Phys Procedia2013; 41: 835–842.
69.
LiRLiuJShiY, et al.Balling behavior of stainless steel and nickel powder during selective laser melting process. Int J Adv Manuf Technol2012; 59: 1025–1035.
70.
GuDShenY. Processing conditions and microstructural features of porous 316L stainless steel components by DMLS. Appl Surf Sci2008; 255: 1880–1887.
71.
de DamboreneaJJLarosaMAArenasMA, et al.Functionalization of Ti6Al4V scaffolds produced by direct metal laser for biomedical applications. Mater Des2015; 83: 6–13.
72.
ContaldiVPasqualeCFrancescoDR, et al.Direct metal laser sintering of Ti-6Al-4V parts with reused powder. Int J Adv Manuf Technol2022; 120: 1013–1021.
73.
SrinivasanDSinghAReddyAS, et al.Microstructural study and mechanical characterisation of heat-treated direct metal laser sintered Ti6Al4V for biomedical applications. Mater Technol2022; 37: 260–271.
74.
Kumar Singh ChauhanAShuklaM. Residual stress modeling and simulation of direct metal laser sintered Ti-6Al-4V alloy. Mater Today Proc2019; 18: 5189–5195.
75.
GhoshSKSahaPKishoreS. Influence of size and volume fraction of SiC particulates on properties of ex situ reinforced Al-4.5Cu-3Mg metal matrix composite prepared by direct metal laser sintering process. Mater Sci Eng A2010; 527: 4694–4701.
76.
HollanderDAvon WalterMWirtzT, et al.Structural, mechanical and in vitro characterization of individually structured Ti-6Al-4V produced by direct laser forming. Biomaterials2006; 27: 955–963.
77.
LeeWHHyunCY. XPS study of porous dental implants fabricated by electro-discharge-sintering of spherical Ti-6Al-4V powders in a vacuum atmosphere. Appl Surf Sci2006; 252: 4250–4256.
78.
LeeWHHyunCY. Fabrication of fully porous and porous-surfaced Ti-6Al-4V implants by electro-discharge-sintering of spherical Ti-6Al-4V powders in an one-step process. J Mater Process Technol2007; 189: 219–223.
79.
GuptaAHussainMMisraS, et al.Processing and characterization of laser sintered hybrid B4C/cBN reinforced Ti-based metal matrix composite. Opt Lasers Eng2018; 105: 159–172.
80.
MisraSHussainMGuptaA, et al.Fabrication and characteristic evaluation of direct metal laser sintered SiC particulate reinforced Ti6Al4V metal matrix composites. J Laser Appl2019; 31: 012005.
81.
GhoshSKBandyopadhyayKSahaP. Development of an in-situ multi-component reinforced Al-based metal matrix composite by direct metal laser sintering technique—optimization of process parameters. Mater Charact2014; 93: 68–78.
82.
AmanovASasakiSChoI-S, et al.An investigation of the tribological and nano-scratch behaviors of Fe–Ni–Cr alloy sintered by direct metal laser sintering. Mater Des2013; 47: 386–394.
83.
IslamMFarhatZN. The influence of porosity and hot isostatic pressing treatment on wear characteristics of cast and P/M aluminum alloys. Wear2011; 271: 1594–1601.
84.
NasrEAKamraniAAl-AhmariA, et al.Digital design and fabrication of customized mandible implant. In: 2014 World Automation Congress (WAC). Waikoloa, HI: IEEE, 2014; pp.1–6.
85.
GongXAndersonTChouK. Review on powder-based electron beam additive manufacturing technology. Manuf Rev2014; 1: 2.
86.
HeinlPMüllerLKörnerC, et al.Cellular Ti-6Al-4V structures with interconnected macro porosity for bone implants fabricated by selective electron beam melting. Acta Biomater2008; 4: 1536–1544.
87.
ChandramohanPBheroSManikandasubramanianK, et al.A Review of Additive Manufacturing of α-β TI Alloy Components Through Selective Laser Melting and Laser Metal Deposition. 13.
88.
JamshidiniaMWangLTongW, et al.Fatigue properties of a dental implant produced by electron beam melting ® (EBM). J Mater Process Technol2015; 226: 255–263.
89.
HaraDNakashimaYSatoT, et al.Bone bonding strength of diamond-structured porous titanium-alloy implants manufactured using the electron beam-melting technique. Mater Sci Eng C2016; 59: 1047–1052.
GaleJAchuhanA. Application of ultrasonic peening during DMLS production of 316L stainless steel and its effect on material behavior. Rapid Prototyp J2017; 23: 1185–1194.
94.
SingSLYeongWY. Laser powder bed fusion for metal additive manufacturing: perspectives on recent developments. Virtual Phys Prototyp2020; 15: 359–370.
95.
RazaviSMJAskesHBertoF, et al.Length scale parameters to estimate fatigue lifetime of 3D-printed titanium alloy Ti6Al4V containing notches in the as-manufactured condition. Int J Fatigue2023; 167: 107348.
96.
AnandMDasAK. Issues in fabrication of 3D components through DMLS technique: a review. Opt Laser Technol2021; 139: 106914.
97.
AcquestaAMonettaT. As-built EBM and DMLS Ti-6Al-4V parts: topography–corrosion resistance relationship in a simulated body fluid. Metals (Basel)2020; 10: 1015.
98.
KeresztesZPammerD. Mechanical properties of Ti-6Al-4V samples produced with additive technology. Mater Today Proc2018; 5: 26558–26565.
E28 Committee. Test Methods for Tension Testing of Metallic Materials. ASTM International, 2022.
101.
E08 Committee. Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials. ASTM International, 2021.
102.
MercelisPKruthJ. Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyp J2006; 12: 254–265.
103.
ZhaoXIyerAPromoppatumP, et al.Numerical modeling of the thermal behavior and residual stress in the direct metal laser sintering process of titanium alloy products. Addit Manuf2017; 14: 126–136.
104.
Ghasri-KhouzaniMPengHRoggeR, et al.Experimental measurement of residual stress and distortion in additively manufactured stainless steel components with various dimensions. Mater Sci Eng A2017; 707: 689–700.
105.
ChandramohanPRaghuRPradeesh KumarD. Laser additive manufactured Ti-6Al-4V alloy: anodizing and its effects on mechanical properties and corrosion resistance. Mater Werkst2020; 51: 1258–1266.
106.
ŻebrowskiRWalczakMKlepkaT, et al.Effect of the shot peening on surface properties of Ti-6Al-4V alloy produced by means of DMLS technology. Eksploat Niezawodn – Maint Reliab2018; 21: 46–53.
107.
MahloboMGRChikoshaLOlubambiPA. A study of the corrosion properties of powder rolled Ti-6Al-4V alloy applied in the biomedical implants. J Mater Res Technol2022; 18: 3631–3639.
108.
ChandramohanPBheroSVarachiaF, et al.Laser additive manufactured Ti-6Al-4V alloy: heat treatment studies. Trans Indian Inst Met2018; 71: 579–587.
109.
DehgahiSGhonchehMHHadadzadehA, et al.The role of titanium on the microstructure and mechanical properties of additively manufactured C300 maraging steels. Mater Des2020; 194: 108965.
110.
MullisAMFarrellLCochraneRF, et al.Estimation of cooling rates during close-coupled gas atomization using secondary dendrite arm spacing measurement. Metall Mater Trans B2013; 44: 992–999.
111.
DebRoyTWeiHLZubackJS, et al.Additive manufacturing of metallic components – process, structure and properties. Prog Mater Sci2018; 92: 112–224.
112.
EnnetiRKMorganRWolfeT, et al.Direct metal laser sintering/selective laser melting of tungsten powders. Int J Powder Metall2017; 53: 23–31.
